Problem Oriented Simulation of Heating Stage in Technological Chain for Metal Hot Forming

2014 ◽  
Vol 698 ◽  
pp. 203-208
Author(s):  
Yuliya Pleshivtseva ◽  
Stepan Korshikov ◽  
Evgenjj Makarov
Keyword(s):  
Induction Heating ◽  
Fem Analysis ◽  
Heating System ◽  
Hot Forming ◽  
Design Parameters ◽  
Heating Stage ◽  
Distributed Parameters ◽  
Technological Chain ◽  
Process Chains ◽  
Forged Parts

Most high duty parts used in various fields of productions are forged parts made of steel. The conventional forging process chains include an induction heating systems and hot forming equipment. The large amount of consumed energy and an excess of material (flash) are the main factors motivating necessity to optimize the industrial technologies of metal hot forming. A significant economical effect can be achieved through optimization of heating modes and design parameters of induction heaters on the basis of modern optimal control theory for distributed parameters systems. The aim of the presented research is a problem-oriented simulation of induction heating stage in the forging chain. 2D ANSYS model provides FEM analysis of interrelated electromagnetic, temperature and thermal stress fields during induction heating of a steel cylindrical billet before its hot forming. The model has interface adapted to optimization procedures; it provides more options for variation of the heating system parameters or billet geometry and material properties, and for evaluating the process optimization abilities.

Optimization of Induction Heating Regarding Typical Quality Criteria: Problem Solution Based on 2D FEM Analysis

2015 ◽  
Vol 792 ◽  
pp. 462-467 ◽  
Author(s):  
Yuliya Pleshivtseva ◽  
Bernard Nacke ◽  
Anton Popov
Keyword(s):  
Optimal Control ◽  
Control Theory ◽  
Induction Heating ◽  
Optimal Control Theory ◽  
Quality Criteria ◽  
Fem Analysis ◽  
Hot Forming ◽  
Electrical Heating ◽  
Design Parameters ◽  
Distributed Parameters

One of the most widespread methods of heating is induction mass heating because it offers certain advantages over similar technologies, including convectional and electrical heating. A significant economical effect can be achieved through optimization of heating modes and design parameters of induction heaters on the basis of modern optimal control theory for distributed parameters systems. The paper is devoted to the numerical simulation and optimal with respect to typical quality criteria control of thermal modes for metals induction heating before hot forming operations. Two-dimensional non-linear time-optimal control problem, problem of maximum heating accuracy and problem of minimum energy consumption are formulated and reduced to the mathematical programming problems. Optimization procedures are based on the developed at SamSTU alternance method of optimal control theory for distributed parameters systems. 2D FLUX code provides FEM analysis of interrelated electromagnetic and temperature fields during induction heating of a cylindrical billet before its hot forming. The model integrated into optimization procedures provides options for variation of the heating system parameters or billet geometry, and for evaluating the process optimization abilities. Computational results for optimal heating of aluminum cylindrical billets are shown and analyzed.

A Parametric Optimization Approach of an Induction Heating System for Energy Consumption Reduction

2017 ◽  
Author(s):  
Paolo Cicconi ◽  
Anna Costanza Russo ◽  
Mariorosario Prist ◽  
Francesco Ferracuti ◽  
Michele Germani ◽  
...  
Keyword(s):  
Energy Consumption ◽  
Induction Heating ◽  
Heating System ◽  
High Energy ◽  
Design Parameters ◽  
Optimization Approach ◽  
Multi Objective Optimization ◽  
Molding Process ◽  
Multi Objective ◽  
Induction Heating System

Nowadays, electromagnetic high-frequency induction is very used for different non-contact heating applications such as the molding process. Every molding process requires the preheating and the thermal maintenance of the molds, to enhance the filling phase and the quality of the final products. In this context, an induction heating system, mostly, is a customized equipment. The design and definition of an induction equipment depends on the target application. This technology is highly efficient and performant, however it provides a high-energy consumption. Therefore, optimization strategies are very suitable to reduce energy cost and consumption. The proposed paper aims to define a method to optimize the induction heating of a mold in terms of time, consumption, and achieved temperature. The proposed optimization method involves genetic algorithms to define the design parameters related to geometry and controller. A test case describes the design of an induction heating system for a polyurethane molding process, which is the soles foaming. This case study deals with the multi-objective optimization of parameters such as the geometrical dimensions, the inductor sizing, and the controller setting. The multi-objective optimization aims to reduce the energy consumption and to increase the wall temperature of the mold.

scholarly journals OPTIMAL INDUCTOR DESIGN FOR SURFACE HARDENING OF CYLINDRICAL BILLETS BASED ON NUMERICAL TWO-DIMENSIONAL MODEL

2019 ◽  
pp. 40-50
Author(s):  
Yuliya Edgarovna Pleshivtseva ◽  
Anton Valerjevich Popov ◽  
Mariya Aleksandrovna Popova ◽  
Maxim Yurjevich Derevyanov
Keyword(s):  
Optimal Design ◽  
Induction Heating ◽  
Operation Mode ◽  
Heating Time ◽  
Temperature Fields ◽  
Maximum Temperature ◽  
Design Parameters ◽  
Distributed Parameters ◽  
Heating Installation ◽  
And Control

Contemporary industrial production widely uses induction heating prior to the plastic deformation and heat treatment operations due to the benefits it provides in comparison with other types of heating technologies. In order to increase the efficiency of induction heating units and develop their operation mode, the research should be directed towards new design solutions in optimizing constructive parameters of inductors and control algorithms of heating processes. The main goal of the research is developing the best inductor design, which provides maximum temperature uniformity in the surface layer of the billet at the end of heating time. There has been formulated the problem of the inductor unit optimal design with respect to steel cylindrical billets, which can be solved by using the alternance method of parametric optimization of the systems with distributed parameters. Design parameters of the induction heating installation that include the geometry features and the current of power supply are considered as optimized parameters. Software package FLUX was used for developing 2D numerical model of interrelated magnetic and temperature fields in the process of induction heating to describe the system ‘induction heater - billet’. The results of numeric solution of the problem of optimal design have been analyzed.

Innovative electrotechnological systems to provide the temperature modes of technological pipelines

2019 ◽  
Vol 2 (1) ◽  
pp. 29-39 ◽  
Author(s):  
S. G. Konesev ◽  
P. A. Khlyupin
Keyword(s):  
Induction Heating ◽  
Thermal Exposure ◽  
Heating System ◽  
The Arctic ◽  
Process Conditions ◽  
Heating Systems ◽  
Fluid Properties ◽  
Low Efficiency ◽  
Extreme North ◽  
Induction Heating System

Introduction: the systems of thermal effects on thermo-dependent, viscous and highly viscous liquids under conditions of the Arctic and the Extreme North are considered. Low efficiency and danger of heating systems based on burned hydrocarbons, heated liquids and steam are shown. Electrothermal heating systems used to maintain thermo-dependent fluids in a fluid state are considered. The evaluation of the effectiveness of the application of the most common electrothermal system — heating cables (tapes). The most effective electrothermal system based on induction technologies has been determined. Materials and methods: considered methods of thermal exposure to maintain the fluid properties of thermo-dependent fluids at low extreme temperatures. Results: presents an induction heating system and options for its implementation in the Extreme North and the Arctic. Conclusions: induction heating system to minimize loss of product quality, improve the system performance under changing process conditions, eliminate fire product, to reduce the influence of the human factor.

Dimensionamiento de un horno de fundición por inducción electromagnética y cálculo de los parámetros eléctricos

2019 ◽  
pp. 1-15
Author(s):  
Arnulfo Pérez-Pérez ◽  
Jorge Sergio Téllez-Martínez ◽  
Gregorio Hortelano-Capetillo ◽  
Jesús Israel Barraza-Fierro
Keyword(s):  
Induction Heating ◽  
Power Supply ◽  
Electromagnetic Induction ◽  
Cast Steel ◽  
Electrical Power ◽  
Heating System ◽  
Heating Time ◽  
Ferrous Alloys ◽  
Electromagnetic Induction Heating ◽  
Induction Heating System

In this work, the dimensions of a furnace for melting of ferrous alloys were determined. The furnace has an electromagnetic induction heating system. In addition, the parameters of electrical power supply such as frequency and power were calculated. A 5kg cast steel mass with a density of 7.81 kg / dm3 was proposed. This corresponds to a crucible volume of 0.641 dm3. The frequency was obtained from tables, which take into account the diameter of the crucible, and its value was 1 KHz. The energy consumption was determined with the heat required to bring the steel to the temperature of 1740 K, the energy losses through the walls, bottom and top of the crucible. This value was divided between the heating time (30 minutes) and resulted in a power of 4.5 KW. The development of the calculations shows that the induction heating is an efficient process and allows a fast melting of ferrous alloys.

Advanced induction heating system for hot stamping

2018 ◽  
Vol 99 (1-4) ◽  
pp. 583-593 ◽  
Author(s):  
Dong Kyu Kim ◽  
Young Yun Woo ◽  
Kwang Soo Park ◽  
Woo Jeong Sim ◽  
Young Hoon Moon
Keyword(s):  
Induction Heating ◽  
Hot Stamping ◽  
Heating System ◽  
Induction Heating System

Determination of levitated molten metal shape in axisymmetric induction heating system using sensitivity analysis

1995 ◽  
Vol 31 (3) ◽  
pp. 2158-2161 ◽  
Author(s):  
Ghun-Deok Suh ◽  
Hong-Bae Lee ◽  
Song-Yop Hahn ◽  
Tae-Kyung Chung ◽  
Il-Han Park
Keyword(s):  
Sensitivity Analysis ◽  
Molten Metal ◽  
Induction Heating ◽  
Heating System ◽  
Induction Heating System ◽  
Metal Shape

Application of Combined Casting-Forging Process for Production of Durable Lightweight Aluminum Parts

2013 ◽  
Vol 554-557 ◽  
pp. 264-273 ◽  
Author(s):  
Stanislav Dedov ◽  
Gunter Lehmann ◽  
Rudolf Kawalla
Keyword(s):  
Heat Treatment ◽  
High Performance ◽  
High Strength ◽  
High Energy ◽  
Process Efficiency ◽  
Light Weight ◽  
Technological Chain ◽  
Process Chains ◽  
Coupled Process ◽  
Hardening Heat Treatment

Due to the constant development in the automotive industry, where high performance shared with the maximal comfort and safety at low car body weight are the primary goals, gains the lightweight construction in importance. Materials with light weight, high strength and toughness are being engaged. With this background the material aluminum and its alloys become highly attractive to manufacturers. There are mainly two ways of forming the metal materials: casting or forming. Apart from substitution of one method by another there are also many examples of combining of casting and forging processes in practice. Such approach allows using the advantages of both methods, shortening the process chains and saving energy and resources at the same time. Furthermore the form flexibility can be increased and the product quality can be improved. For higher process efficiency a direct transition from casting to forging operation should be applied, so that the heat loss decreases and no additional heat treatment between these operations is necessary. There are processes known, which allow producing the final parts by casting and forging from one a single heat. The application of such processes requires materials, which have simultaneously good casting and forging properties. The Institute of Metal forming TU Freiberg works intensively on development of combined casting-forging technologies for lightweight aluminum parts. A technological chain for this coupled process followed by precipitation hardening heat treatment was developed (Figure 1). Heat treatable aluminum cast and wrought alloys with 1 – 7 % silicon were applied. By the variation of silicon content the optimal cast, forging and hardening properties were achieved. This technology with high energy efficiency allows producing durable light weight parts from aluminum alloys while the mechanical properties of the final parts are equal to or even higher than those in the conventional processes.

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